OPERATING AND INSTALLATION INSTRUCTIONS Models 136-1826 CATALOG NO.: RM-001 Effective : 01-15-02 Replaces: 03-15-01 MODEL SERIAL NUMBER INSTALLATION DATE START UP DATE FOR YOUR SAFETY Do not store or use gasoline or other flammable vapors or liquids or other combustible materials in the vicinity of this or any other appliance. To do so may result in an explosion or fire. WARNING Improper installation, adjustment, alteration, service or maintenance can cause property damage, personal injury or loss of life. Refer to the user's information manual provided with this heater. Installation and service must be performed by a qualified installer, service agency or the gas supplier. FOR YOUR SAFETY WHAT TO DO IF YOU SMELL GAS * Do not try to light any appliance. * Do not touch any electrical switch; do not use any phone in your building. * Immediately call your gas supplier from a neighbor's phone. Follow the gas supplier's instructions. * If you cannot reach your gas supplier, call the fire department. IMPORTANT WARNING THE HEATER MUST BE INSTALLED IN ACCORDANCE WITH THE INSTRUCTIONS IN THIS MANUAL. WAR- RANTY WILL NOT APPLY TO UNITS NOT INSTALLED, OPERATED OR MAINTAINED ACCORDING TO THESE INSTRUCTIONS. THE INSTALLATION MUST CONFORM TO THE AUTHORITIES HAVING JURISDICTION AND/ OR WITH THE LATEST EDITIONS OF THE NATIONAL FUEL GAS CODE ANSI Z223.1, THE NATIONAL ELECTRIC CODE ANSI/NFPA 70. Rheem Commercial Water Heater Products Ruud Commercial Water Heater Products One Bell Road Montgomery, AL 36117 (205) 260-1500 Part No. 240454
INDEX 3 COPPER SANIMASTER AND TYPHOON HOT WATER HEATERS 4 Specification Data 7 INTRODUCTION INSTALLATION GUIDELINES 8 Base Requirements 9 Combustible Construction Clearances 10 Combustion Air Supply Outdoor Venting 12 Indoor Venting 16 Power Venting Outdoor Heaters Vent Damper Installation 18 Piping (Gas and Water) 20 Cold Water Supply 21 Hot Water Supply Heater 22 Piping Diagram - 1 Heater 1 Tank Thermostat Supplied 23 Piping Diagram - 1 Heater 2 Tank 24 Piping Diagram - 1 Heater 3 Tank 25 Piping Diagram - 1 Heater 4 Tank 26 Piping Diagram - 2 Heater 1 Tank Uses Special Thermostat & Well 27 Description of Controls in General Operating Controls 28 Tankstat Temperature Control 29 Electrical 29 Start-Up 30 General Safety Precautions 31 Lighting Instructions 33 Inspection and Maintenance Procedures Burner Inspection 34 Venting System Inspection Circulator (Water Pump) Inspection Service Assistance 35 Trouble Shooting 39 Wiring Diagram 44 Replacement Parts List 2
COPPER SANIMASTER AND TYPHOON HOT WATER HEATERS Series GB for circulating tank systems 136 through 1826 MBTUH Model Applications Hot water Supply Heaters are designed to provide hot water service to a variety of applications when used in conjunction with an appropriately sized storage tank. Models are available for indoor or outdoor installations, and controls and pump are factory tested and mounted.* Construction Features 1. All copper high efficiency heat exchanger. 2. Factory mounted pump suited for a wide variety of water conditions.* 3. Flow Switch included on all models. 4. All models feature an energy saving pump control. 5. Glass-lined cast iron headers to handle the most aggressive water conditions.+ 6. All units are tested and certified to ANSI Z21.10.3 and carry National Board Stamps HLW. 7. Factory installed pressure relief valve. 8. Temperature pressure gauge and tankstat are included. 9. All inputs over a 400,000 BTU feature intermittent pilot ignition. 10. Models available for Natural or LP Gas. * Pump shipped separate in carton on Models 136 through 399. + Model 136 features Bronze Headers. 3
SPECIFICATION DATA MBH Natural Gas MODEL STYLE In- Out- Sanimaster Typhoon (Indoor) (Outdoor) 136 181 264 331 399 512 627 726 825 926 962 1083 1125 1178 1223 1287 1337 1413 1467 1570 1630 1758 1826 Door Door Input Output Input Output 136.0 112.0 136.0 112.0 181.0 148.0 181.0 148.0 264.0 216.0 264.0 216.0 334.0 274.0 334.0 274.0 399.0 327.0 399.0 327.0 511.5 419.4 511.5 419.4 627.0 514.0 627.0 514.0 726.0 595.0 726.0 595.0 825.0 676.5 825.0 676.5 926.0 759.0 961.7 788.6 1083.0 888.0 1124.7 922.0 1178.0 966.0 1222.5 1002.4 1287.0 1055.0 1336.6 1096.0 1413.0 1158.5 1467.0 1203.0 1570.0 1287.0 1630.0 1336.6 1758.0 1441.5 1825.6 1497.0 ELECTRICAL RATINGS Model Size With Pump 136-264 3.4 amps @ 120V(1/8 hp pump) 331-399 3.6 amps @ 120V(1/6 hp pump) 512-1826 7.9 amps @ 120V (1/2 hp pump) MBTUH PROPANE GAS Model Size Multiplier 136-399 Same as natural gas 512-825.94 926-1826.92 Indoor.955 Outdoor (Input).92 Outdoor (Output) Multiplier x Nat. MBTUH = Pro. MBTUH Rated inputs are suitable for up to 2000 feet elevation. For elevations above 2000 feet, reduce input 4% for each 1000 feet above sea level. These heaters are tested and certified to ANSI Standard Z 21.10.3 4
5
Jacket Height C 30-1/8 38 38 38 38 33 33 33 33 33-1/2 33-1/2 33-1/2 33-1/2 33-1/2 36-1/2 36-1/2 Gas Conn. G 1/2 3/4 3/4 3/4 3/4 1 1 1 1 1 1 1 1 1 1 1-1/4 1-1/4 1-1/4 1-1/4 1-1/4 1-1/4 1-1/4 1-1/4 Water Connection H 1-1/4 1-1/2 1-1/2 1-1/2 1-1/2 2 2 2 2 2-1/2 2-1/2 2-1/2 2-1/2 2-1/2 2-1/2 2-1/2 2-1/2 2-1/2 2-1/2 2-1/2 2-1/2 2-1/2 2-1/2 J 12-1/16 11-1/8 10-3/4 12-1/2 23-5/8 23-5/8 23-5/8 23-5/8 23-5/8 23-5/8 23-5/8 Reference to Drawing 1 2 3 4 L 9-1/4 25-3/8 29-1/2 34-1/4 38-1/2 28 32 32 36 36 36 40 Width A 24-1/8 18-1/4 22-3/8 25-3/4 29-1/4 32-3/4 37-1/2 41-5/8 45-3/4 52-3/8 52-3/8 59-1/4 59-1/4 63-5/8 63-5/8 68-5/8 68-5/8 74-7/8 74-7/8 81-1/8 81-1/8 89-3/8 Height Overall B 45 62-5/8 62-7/8 63-3/4 65-3/8 57 57 57 57 76-1/8 78-1/8 78-1/8 80-1/8 80-1/8 83-1/8 85-1/8 Flue Dia. K 6 6 7 8 9 10 12 12 14 14 16 16 18 18 18 20 SHIPPING WEIGHT LBS (APPROX) Less Pump 160 182 205 225 244 475 485 635 645 785 705 865 745 925 805 980 875 1080 945 1130 985 1160 1035 W/Pump 210 232 255 275 294 530 540 690 700 840 760 920 800 980 860 1035 930 1130 1000 1190 1040 1220 1090 6 MODEL SIZE 136 181 264 331 399 512 627 726 825 926 962 1083 1125 1178 1223 1287 1337 1413 1467 1570 1630 1758 1826 Indoor Outdoor
A. INTRODUCTION WE RECOMMEND THAT THIS MANUAL BE REVIEWED THOROUGHLY BEFORE INSTALLING THE WATER HEATER. SHOULD ANY QUESTIONS ARISE, NOT COVERED BY THIS DATA, CONTACT YOUR LOCAL DISTRIBUTOR OR THE SERVICE DEPARTMENT AT THE FACTORY. MODEL IDENTIFICATION The model number of the water heater is found on the rating plate. Each model number identifies the application, the construction and the function of the water heater, and provides a positive means of identification for application, installation, operation, service and parts of the unit in a minimum amount of time. RECEIVING EQUIPMENT On receiving equipment it is suggested that you Review packing slip for the number of packages. Inspect for concealed damage immediately. Advise carrier, in writing, of shortages or damage. Claims are filed by the receiver against the carrier. The carrier, not the shipper, is responsible for any shortage or damage whether visible or concealed. B. INSTALLATION GUIDELINES INSTALLATION REGULATIONS THE INSTALLATION MUST CONFORM WITH THESE INSTRUCTIONS, REQUIREMENTS OR CODES OF AUTHORITIES HAVING JURISDICTION, THE LATEST EDITION OF THE NATIONAL FUEL GAS CODE, ANSI Z223.1 AND THE NATIONAL ELECTRICAL CODE. ANY ALTERATION OR MODIFICATION TO THE WATER HEATER, ITS COMPONENTS OR ITS INTENDED APPLICATION MAY VOID THE WARRANTY EXTENDED WITH THE PRODUCT BY THE MANUFACTURER. WARNING: Improper installation, adjustment, alteration, service or maintenance can damage the water heater, or create a hazard resulting in asphyxiation, explosion or fire. WATER FLOW Low water content heat exchangers require continuous flow for proper operation. WATER CONDITIONS: Domestic Hot water heaters are designed for operation with various water conditions. Corrosive water that has high chlorine content or other chemicals require that the tubes in the heat exchanger be cupro-nickel. Provide us with an analysis of water where this potential exists. 7
BASE REQUIREMENTS Indoor water heaters must be installed on a level noncombustible surface, except as noted below. Do not install on carpeting. Heater sizes 926 to 1758 Typhoon (Outdoor) are supplied with a combustible flooring base as standard. The following chart lists the part number required for a combustible base, for water heaters supplied without a combustible base. COMBUSTIBLE FLOOR BASE BOILER PART BOILER PART BOILER PART BOILER PART 136 001749 399 058316 825 056202 1337 059236 181 058313 512 056199 962 059233 1467 059237 264 058314 627 056200 1125 059234 1630 059238 331 058315 726 056201 1223 059235 1826 059239 Fig. #8148.1 Fig. #8276 Hollow concrete cinder block; align holes and leave ends open. Alternative method for providing a non-combustible base. HEATER WITH COMBUSTIBLE FLOOR SHIELD HEATER INSTALLATION ON CONCRETE BLOCKS OR TILE 8
COMBUSTIBLE CONSTRUCTION CLEARANCES The water heater should be positioned to provide the minimum clearances from combustible surfaces and to provide sufficient space for servicing the unit as follows. MINIMUM CLEARANCES: PROTECTED SURFACES Clearances to surfaces installed in rooms which are large (2) in comparison with size of heater. Combustible Surfaces (a) 3 1/2-in. thick masonry wall without ventilated air space (b) 1/2-in. insulation board over 1-in. glass fiber or mineral wool batts (c) 0.024 sheet metal over 1-in. glass fiber or mineral wool batts reinforced with wire on rear face with ventilated air space (d) 3 1/2-in. thick masonry wall with ventilated air space (e) 0.024 sheet metal with ventilated air space (f) 1/2-in. thick insulation board with ventilated air space (g) 0.024 sheet metal with ventilated air space over 0.024 metal with ventilated air space (h) 1-in. glass fiber or mineral wool batts sandwiched between two sheets 0.024 sheet metal with ventilated air space Rear 12" 9 6 4 6 4 4 4 4 Left Side 12" 9 6 4 6 4 4 4 4 136 Right Side 6" 5 3 3 6 2 3 3 3 Indoor Top 42" 42 42 42 42 42 42 42 42 Rear 12" 9 6 4 6 4 4 4 4 Left Side 12" 9 6 4 6 4 4 4 4 181-399 Right Side 12" 9 6 4 6 4 4 4 4 Indoor Top 39" 39 39 39 39 39 39 39 39 Outdoor Top(1) Rear 12 9 6 4 6 4 4 4 4 Left Side 18 12 9 6 6 6 6 6 6 512-825 Right Side 6 5 3 3 6 2 3 3 3 Indoor Top 36 36 36 36 36 36 36 36 36 Outdoor Top (1) Rear 24 16 12 8 8 8 8 8 8 Left Side 24 16 12 8 8 8 8 8 8 926-1826 Right Side 24 16 12 8 8 8 8 8 8 Indoor Top 24 24 24 24 24 24 24 24 24 Outdoor Top (1) (1) Unobstructed. (2) Large rooms are defined as having a volume at least 16 times the total volume of the heater. (3) Installation clearances for heaters in rooms not large in comparison with the heater size shall be as listed under combustible surfaces and shall not be reduced by the protection methods. SERVICING CLEARANCES: 24" in front of heater for removal of burner tray. 18" on side opposite water connection for deliming of Heat Exchanger on Models 181-1826 only. 9
COMBUSTION AND VENTILATION AIR SUPPLY CAUTION: Combustion air must not be contaminated by corrosive chemical fumes which can damage the heater and void the warranty. IMPORTANT: Adequate air must be provided for proper combustion and ventilation of the surrounding area. An inadequate supply of combustion air will result in incomplete combustion and eventual sooting of the heater. Insufficient ventilation will cause excessive heat and rapid deterioration of electronic and electrical components. Equipment rooms should be provided with TWO permanent air supply openings directly connected to outside air. Each opening must have a minimum FREE area of one square inch per 4000 BTU per hour input of the total input rating of all equipment in the room. Local codes or authorities having jurisdiction should be consulted for the following table. RECOMMENDED MINIMUM AIR OPENINGS NET NET NET BOILER FREE BOILER FREE BOILER FREE SIZE AREA SIZE AREA SIZE AREA 136 34 512 128 1125 282 181 47 627 157 1223 306 264 66 726 182 1337 335 331 84 825 207 1467 367 399 100 962 241 1630 408 All area shown in square inches 1826 457 For other conditions refer to the latest edition of the National Fuel Gas Code ANSI Z 223.1. Net free area, sq. in. requires data from louver manufacturer based on resistance of screening, if provided. OUTDOOR INSTALLATIONS MODEL 136 MODEL 181-399 Step 1: Remove the front (4) screws Step 2: Line up outdoor top vent opening over heater vent opening. Step 3: Lower outdoor top onto unit lining up slots in the outdoor top with screws holes in jacket top. Step 4: Reinstall (5) screw to secure jacket top and outdoor top to unit. VENT TERMINAL (Outdoor) Stackless Top Installation 1. Insert tabs into keyhole (4 places). Pagoda Top (Shipped Loose with Heater) Fig. # 8114 10
2. Snap tabs into keyholes so as not to pull out. MODELS 926-1758 Heater shipped with outdoor vent terminal factory installed. INDOOR HEATERS Indoor Installations MODEL 136 MODELS 512-825 Step 1: Lower outdoor "Stackless" top on to unit. Position top so it is centered on unit from side to side and front to rear. Step 1: Shut off main electrical per switch to heater. Step 2: Turn heater manual switch located in upper control panel to the "OFF" position. Step 3: Shut off gas supply and water supply to the heater. Step 4: Mount drafthood on boiler and attach with the 4 sheet metal screws provided. Drafthood should be positioned with the vent sensor located on the front left side as shown. Step 5: Remove plastic plug from left side of boiler jacket and install the plastic grommet provided. Step 6: Route flue sensor wire harness through the grommet installed in Step 5. TEMPERATURE SENSOR SENSOR SHIELD MOUNTING JACKET SCREWS TOP HARNESS CONTROL ASSY. PANEL HEATER ON/OFF SWITCH Fig. # 8166.1 Step 2: Tighten the (4) screws (Shown below) until they come in contact with the unit jacket top, then evenly tighten all (4) screws to secure to unit. GROMMET LOWER DOOR Fig. # 8946 JACKET TOP FASTENING SCREW Fig. # 8233 11
Step 7: Remove door and locate wire from roll out sensor to Hi Limit with the male/female connector. Fig. #8947 Step 8: Disconnect male/female connector and attach to the 2 wires from drafthood vent sensor harness. MODELS 181-399 VENT TERMINAL/INDOOR STACK INSTALLATION 1. Remove the louvered jacket top by removing four (4) #10 flat head screws. 2. If originally installed, remove "Pagoda" top from the louvered jacket top. 3. Place the inner stack adapter panel over the flue collector inside the heater. Make sure the flanged side of the flue opening is up. 4. Turn the stack (draft hood) up side down and set it down bottom side up. 5. Turn the jacket top panel (removed in step 1) up side down and place it through the stack. DRAFTHOOD 6. Attach the three (3) mounting brackets to the stack using the screws provided and the holes that are pre-drilled in the stack. Make sure the brackets are positioned with the flange near the top side of the stack (see illustration). Caution must be taken not to over tighten and strip the screw threads. 7. Turn the assembled stack and jacket top, right side up. The jacket top will be trapped between the brackets and the top of the stack. Place the stack over the inner adapter panel flanged hole and lower the louvered jacket top panel back into its original position. Reinstall the four (4) green #10 flat head screws removed in step 1 above. SCREW HOLE LOCATION 3-1/4" JACKET TOP PANEL (part of the heater) #10 SHEET METAL SCREW (3) MOUNTING BRACKET (3) INNER STACK ADAPTER PANEL FLUE COLLECTOR (part of heater) Fig. #8246.5 12
MODELS 181-399 Step 1. Shut off main electrical power switch to heater. Step 2. Turn heater manual switch located in upper control panel to the "OFF" position. Step 3. Shut off gas supply and water supply to the heater. Step 4. Mount drafthood on top of boiler as shown on page 8. Drafthood should be positioned with the vent sensor located on the front right side as shown. Step 5. Remove plastic plug from left side of boiler jacket and install plastic grommet provided. Step 6. Route flue sensor wire harness through the grommet installed in Step 5. Step 7. Remove door and locate wire from roll out sensor to hi limit with the male/female connector. Step 8. Disconnect male/female connector and attach to the 2 wires from draft hood vent sensor harness. Fig# 9349 Fig# 9350 HEATER BEFORE DRAFTHOOD INSTALLATION HEATER AFTER DRAFTHOOD INSTALLATION MODELS 512-825 Locate and assemble as shown below. Secure with screws supplied in envelope in carton Fig. #8167.0 13
MODELS 962-1826 Locate and assemble as shown below. Secure with screws supplied in envelope in carton. Fig. #8265.0 WARNING: Indoor heaters require a drafthood that must be connected to a vent pipe and properly vented to the outside. Failure to follow this procedure can cause fire or fatal carbon monoxide poisoning. Vent piping the same size or larger than the draft hood outlet is recommended, however, when the total vent height is at least ten (10) feet (draft hood relief opening to vent terminal), the vent pipe size may be reduced as specified in Chapter 10 of the National Fuel Gas Code, ANSI Z223.1. As much as possible avoid long horizontal runs of vent pipe and too many elbows. If installation requires horizontal non-vertical runs, the vent pipe must have a minimum of 1/4 inch per foot rise and should be supported at not less than five foot intervals. Plumbers tape, criss-crossed, will serve to space both horizontal and vertical piping. Gas vents supported only by the flashing and extending above the roof more than five feet should be securely guyed or braced to withstand snow and wind load. We recommend use of insulated vent pipe must terminate with a vent cap which complies with the local codes or, in the absence of such codes, to the latest edition of the National Fuel Gas Code, ANSI Z223.1. The discharge opening must be a minimum of three feet vertically from the roof surface and at least two feet higher than any part of the building within ten feet. Vent stack shall be at least five 10' OR LESS VENT CAP feet in vertical height above the drafthood outlet. The vent cap location shall have a minimum clearance of 4 feet horizontally from, and in no case above or below, unless a 4-foot horizontal distance 2' MIN 2' MIN is maintained, from electric meters, gas meters regulators and relief equipment. The weight of the vent stack or chimney must not rest on the 5' MIN heater draft hood. Support must be provided in compliance with applicable codes. The heater top and draft hood must be readily VENT PIPE removable for maintenance and inspection. Vent pipe should be adequately supported to maintain proper clearances from combustible construction. Type "B" double wall or equivalent vent pipe is recommended. DRAFT HOOD However single wall metal vent pipe may be used as specified in the latest edition of the National Flue Gas Code ANSI Z223.1. HEATER 14 Fig # 8119
At the time of removal of an existing heater, the following steps shall be followed with each appliance remaining connected to the common venting system placed in operation, while the other appliances remaining connected to the common venting system are not in operation. (a) Seal any unused openings in the common venting system. (b) Visually inspect the venting system for proper size and horizontal pitch and determine there is no blockage or restriction, leakage, corrosion and other deficiencies which could cause an unsafe condition. (c) Insofar as is practical, close all building doors and windows and all doors between the space in which the appliances remaining connected to the common venting system are located and other spaces of the building. Turn on clothes dryers and any appliance not connected to the common venting system. Turn on any exhaust fans, such as range hoods and bathroom exhausts, so they will operate at maximum speed. Do not operate a summer exhaust fan. Close fireplace dampers. (d) Place in operation the appliance being inspected. Follow the lighting instructions. Adjust thermostat so appliance will operate continuously. (e) Test for spillage at the draft hood relief opening after 5 minutes of main burner operation. Use the flame of a match or candle, or smoke from a cigarette, cigar or pipe. (f) After it has been determined that each appliance remaining connected to the common venting system properly vents when tested as outlined above, return doors, windows, exhaust fans, fireplace dampers and any other gas burning appliance to their previous conditions of use. (g) Any improper operation of the common venting system should be corrected so the installation conforms with the latest edition of the National Fuel Gas Code, ANSI Z223.1. When resizing any portion of the common venting system, the common venting system should be resized to approach the minimum size as determined using the appropriate tables in Part 11 of the National Fuel Gas Code, ANSI Z223.1. Manifolds that connect more than one heater to a common chimney must be sized to handle the combined load. Consult available guides for proper sizing of the manifold and the chimney. At no time should the area be less than the area of the largest outlet. Fig. #7043.1 15
POWER VENTING Heaters may be connected to systems requiring mechanical draft exhaust fans. The installation must be engineered by competent personnel in accordance with the latest edition of ANSI Z 223.1, local codes and with the supplier of the fan. Particular attention must be given to the type of vent pipe used, its size and location. Suitable interlocks must be provided to prevent heater operation until the fan is operating as designed. OUTDOOR WATER HEATERS The point from where the flue products exit the heater must be a minimum of four (4) feet below, four (4) feet horizontally from or one (1) foot above any door, window or gravity inlet to a building. The top surface of the heater shall be at least three (3) feet above any forced air inlet, or intake ducts located within ten (10) feet horizontally. Fig. #8245.1 HIGH WIND CONDITIONS (Outdoor Units Only) In areas where high winds are frequent, it may be necessary to locate the heater a minimum of 3' from high vertical walls, or install a wind break so the heater is not in direct wind current. VENT DAMPER INSTALLATION (MODELS 136 THROUGH 264) WHERE REQUIRED LOCATION The vent damper must be located in the vent so that it serves only the appliance for which it is intended. If improperly installed, a hazardous condition, such as an explosion or carbon monoxide poisoning, could result. Make certain that it is mounted in an accessible location at least 6 in. (152.4 mm) from any combustible material or the heat exchanger and that the position indicator is in a visible location. The vent damper must be installed after the appliance draft hood, as close to the draft hood as practicable, and without modification of the draft hood. Fig. # 8182.0 16
MOUNTING On vertical vents, the vent damper may be mounted with the actuator in any position. On horizontal vents, do not mount the actuator either directly above or directly below the vent pipe; mount the vent damper actuator to the side of the vent. The vent damper is set up for a continuous pilot system. If the vent damper is installed on an intermittent Pilot or Direct Spark Ignition equipped system, the energy savings of the vent damper can be improved by plugging the hole in the vent damper blade using the knockout plug, Part No 105612R, provided in the parts envelope. DO NOT plug the hole if installing the vent damper on a continuous pilot system as this will create a hazardous condition. INSTALLING THE VENT DAMPER IN HORIZONTAL & VERTICAL VENTS. D80B GENERAL WIRING DIAGRAM INSTALL THE VENT DAMPER TO SERVICE ONLY THE SINGLE APPLIANCE FOR WHICH IT IS INTENDED. IF IMPROPERLY INSTALLED, A HAZARDOUS CONDITION, SUCH AS AN EXPLOSION OR CARBON MONOXIDE POISONING, COULD RESULT. VENT DAMPER NORMAL OPERATION SUMMARY For safe, efficient operation, the vent damper and all flue product carrying areas of the appliance must be checked annually, with particular attention given to deterioration from corrosion or other sources. Check vent damper operation as follows: THE VENT DAMPER MUST BE INSPECTED AT LEAST ONCE A YEAR BY A TRAINED, EXPERIENCED SER- VICE TECHNICIAN.. THE NAME OF THE PERSON WHO ORIGINALLY INSTALLED YOUR VENT DAMPER IS SHOWN ON THE INSTALLATION LABEL. DAMPER MUST BE IN OPEN POSITION WHEN HEATER MAIN BURNERS ARE OPERATING. Damper position indicator 1. When the furnace or heater is off, check that the vent damper position indicator points to the closed position, Fig. 4. 2. Turn the thermostat or controller up to call for heat and check that the vent damper indicator points to the open position, Fig. 4. 3. Turn the thermostat or controller down again and check that the vent damper position indicator returns to the closed position. DAMPER OPEN DAMPER CLOSED FIG.4-VENT DAMPER POSITION INDICATOR SHOWING OPEN & CLOSED POSITIONS. 17
PIPING: General. Consult particular heater section for specific information. a. GAS Gas piping must be installed in accordance with the latest edition of the National Fuel Gas Code ANSI Z 223.1 and other local or regulatory agency codes that have jurisdiction. 1. Check heater rating plate for Correct Fuel Gas Rated input to meet local conditions such as altitude, gas specification, etc. 2. Piping from meter must be of sufficient size to provide the required amount of gas at flowing pressures as follows: Gas Natural Propane BTU/CF 1000 2500 SP. GR 0.60 1.53 Minimum Flowing Pressure 7" W.C. 12" W.C. Maximum Shut-off Pressure 14" W.C. 14" W.C. PIPE SIZES Fuel Nat. Propane Length(feet) 0-100 100-200 200-300 0-100 100-200 200-300 Model 136 3/4 1 1-1/4 3/4 1 1 181 1 1-1/4 1-1/4 1 1 1-1/4 264 1-1/4 1-1/4 1-1/2 1 1-1/4 1-1/4 331 1-1/4 1-1/2 1-1/2 1-1/4 1-1/4 1/1/2 399 1-1/4 1-1/2 1-1/2 1-1/4 1-1/4 1-1/2 512 1-1/2 2 2 1-1/4 1-1/2 1-1/2 627 1-1/2 2 2 1-1/2 1-1/2 2 726 2 2 2 1-1/2 2 2 825 2 2 2-1/2 2 2 2 926 2 2-1/2 2-1/2 2 2 2 962 2 2-1//2 2-1/2 2 2 2 1083 2 2-1/2 2-1/2 2 2 2 1125 2 2-1/2 2-1/2 2 2 2 1178 2-1/2 2-1/2 3 2 2 2-1/2 1223 2-1/2 2-1/2 3 2 2 2-1/2 1287 2-1/2 3 3 2 2-1/2 2-1/2 1337 2-1/2 3 3 2 2-1/2 2-1/2 1413 2-1/2 3 3 2 2-1/2 2-1/2 1467 2-1/2 3 3 2 2-1/2 2-1/2 1570 2-1/2 3 3 2 2-1/2 3 1630 2-1/2 3 3 2 2-1/2 3 1758 2-1/2 3 3 2 2-1/2 3 1826 2-1/2 3 3 2 2-1/2 3 Chart is based on: 0.5" W.C. Pressure Drop Natural Gas 0.6" W.C. Pressure Drop Propane Gas Fitting provided in gas line have equivalent length of pipe, in feet, as follows: Size 3/4 1 1-1/4 1-1/2 2 2-1/2 3 4 Elbow 2.5 3 4 4.5 5.5 6.5 8 12 Tee 5 6 8 9 12 14 17 22 3. All gas piping must be tested after installation with air or an inert gas and all connections should be checked using a soapy solution. 18
CAUTION: The heater and its manual shut off valve must be disconnected from the gas supply during any pressure testing of that system at test pressures in excess of 1/2 psig (3.45 KPA). Dissipate test pressure in the gas supply line before reconnecting the heater and its manual shut off valve to gas supply line. FAILURE TO FOLLOW THIS PROCEDURE MAY DAMAGE THE GAS VALVE. OVER PRESSURED GAS VALVES ARE NOT COVERED BY WARRANTY. The heater and its gas connections shall be leak tested before placing the appliance in operation. Use soapy water for leak test. Do NOT use open flame. Test piping as follows: Pressure 1/2 PSIG (14" W.C.) or less - isolate heater by closing the manual shut-off valve prior to applying pressure. Pressure in excess of 1/2 PSIG (14" W.C.) - The heater must be disconnected from the gas system. Water heaters having gas train components that have diaphragms in their construction are supplied with a bleed line connection that must be connected to the outside atmosphere as required by the National Fuel Gas Code. Under NO circumstances shall bleed lines terminate in the gas utilization equipment flue or exhaust system. Fig.#8185.1 Burner Manifold Pressures. The gas pressure regulator supplied with the heater is factory set to provide a manifold pressure, as measured with a manometer, of 3.7 in. W.C. for Natural Gas and 10.5 in. W.C. for Propane. If adjustment is required to obtain these pressures remove cap and turn screw clockwise to increase pressure, counter- clockwise to decrease pressure. 19
b. WATER Water piping should be installed according to the local code requirements, ASHRAE, ASPE and BOCA or other regulatory agencies. COLD WATER SUPPLY The cold water supply piping, to the heater must be adequate to handle the design load requirements of the hot water system. The following table illustrates the flow and minimum pipe sizes. Model Size 136 181 264 331 399 512 627 726 Flow GPM 22 30 42 53 63 82 85 85 Min Pipe NPT 1-1/4 1-1/2 1-1/2 1-1/2 1-1/2 2 2 2 Model Size 825 926 962 1083 1125 1178 1287 1337 Flow GPM 85 90 90 90 90 90 90 90 Min Pipe NPT 2 2-1/2 2-1/2 2-1/2 2-1/2 2-1/2 2-1/2 2-1/2 Model Size 1413 1467 1570 1630 1758 1826 Flow GPM 90 90 90 90 90 90 Min Pipe NPT 2-1/2 2-1/2 2-1/2 2-1/2 2-1/2 2-1/2 It is recommended that a gate valve be installed in the cold water supply line adjacent to the heater. If Local Codes require a check valve - provisions must be made for thermal expansion. A minimum pressure of 30 PSIG must be maintained in the system to prevent damage to the heater due to lack of water circulation caused by vapor formation at suction side of the system pumps. NOTE: Should the cold water supply be interrupted, for any reason, the gas supply must be manually shut off to prevent heater damage. When the service is restored the lines must be vented to eliminate accumulated air. 20
HOT WATER SUPPLY HEATER Model 136-1826 The heater is direct fired and used with a storage tank. The model number indicates the BTU/holds input. (i.e. an 1826 holds input of 1,826,000 BTU/ HR) See specification and dimension information on pages 4, 5 and 6. TANK TEMPERATURE CONTROL 1. The tank temperature controller is shipped loose for installation in the field. It is found in the burner tray. 2. Install in the tapping provided in the storage tank as shown. 3. Wire the "TH" leads, provided in the boiler control box, to the tank temperature controller. DO NOT WIRE IN SERIES WITH 115 VOLT SUPPLY TO THE HEATER. NOTE: The "TH" wires are in the 24 volt control circuit. DO NOT connect to the 115 volt circuit. 4. Set temperature to 140 F or to desired tank temperature. 21
SEQUENCE OF OPERATION 1. Power to heater and recirculation pump. 2. Control switch, located on heater control box, placed in "ON" position. a. High limit controller circuit closed. b. Tank temperature controller calls for heat. c. Pump relay energized starting heater pump. d. Flow switch activated, if sufficient flow is determined, sending power to e. The ignition relay, S8600. f. The pilot is energized and when proven lit. g. Spark to pilot stops and h. The main gas opens allowing the burners to light. 3. Tank temperature reaches desired temperature. a. Controller opens circuit. b. Ignition relay de-energizes shutting off main and pilot gas. c. Heater pump continues to operate until residual heat in the heater is dissipated. d. Stack temperature drops below 140 F. A stack sensor, a part of the energy saving control, opens the pump relay circuit shutting down pump. 4. Heater waits for next call for heat. INSTALLATION WATER HEATER PLUMBING: The Recirculation pump, supplied by the installer should be sized according to heater input Model # ie. 825 would require 8.25 GPM. This pump is in addition to the pump supplied with the heater. The pump should be set for constant recirculation. DO NOT WIRE to heater or tank operating controls. PIPING DIAGRAM-1 HEATER 1 TANK THERMOSTAT SUPPLIED Fig. # 8054-RHEEM 22
PIPING DIAGRAM-1 HEATER 2 TANK * PIPING MUST BE EQUAL BETWEEN TEES AND TANKS. NOTES: 1. Plumb all swing check valves in gravity closed position. 2. Minimum pipe size equal to heater inlet/outlet connection size (between heater and tanks). 3. Pipe sizes between tanks are to be based on estimated GPM flow rates (Max. 10 FPS Vel.) 4. Pipe all relief valves to drain or as local codes require. 5. Duplex manifold kit & 115 gallon jacketed and insulated storage tanks available from factory. 23
PIPING DIAGRAM-1 HEATER 3 TANK Fig. # 8067-RHEEM * PIPING MUST BE EQUAL BETWEEN TEES AND TANKS. NOTES: 1. Plumb all swing check valves in gravity closed position. 2. Minimum pipe size equal to heater inlet/outlet connection size (between heater and tanks). 3. Pipe sizes between tanks are to be based on estimated GPM flow rates (Max. 10 FPS Vel.) 4. Pipe all relief valves to drain or as local codes require. 5. Duplex manifold kit & 115 gallon jacketed and insulated storage tanks available from factory. 24
PIPING DIAGRAM-1 HEATER 4 TANK * PIPING MUST BE EQUAL BETWEEN TEES AND TANKS. NOTES: 1. Plumb all swing check valves in gravity closed position. 2. Minimum pipe size equal to heater inlet/outlet connection size (between heater and tanks). 3. Pipe sizes between tanks are to be based on estimated GPM flow rates (Max. 10 FPS Vel.) 4. Pipe all relief valves to drain or as local codes require. 5. Duplex manifold kit & 115 gallon jacketed and insulated storage tanks available from factory. 25
PIPING DIAGRAM-2 HEATER 1 TANK SPECIAL THERMOSTAT AND WELL NOTES: 1. Plumb all swing check valves in gravity closed position. 2. Minimum pipe size to be (1) size larger than heater inlet/outlet connection size. 3. Pipe all relief valves to drain or as local codes require. 4. 115 gallon jacketed and insulated storage tanks available from factory. 5. When two heaters are paralleled, do not use factory supplied thermostats. Order thermostat part number 600887 and Well PN 650590 from factory. See electrical wiring on page 29. 6. Heaters with 2" or 2-1/2" manifold size may require more than one storage tank. Consult factory for proper storage sizes. 26
DESCRIPTION OF CONTROLS IN GENERAL ENERGY SAVING PUMP CONTROL The energy saving pump control is an electronic device that allows the operator to set the desired time for the pump to run after the heater shuts off. The time is factory-set at 7 minutes and it can be re-adjusted in the field anywhere from 3 to 10 minutes. In a conventional system, when the tankstat is satisfied, the main gas valve closes, but the pump continues operating. With the energy saving pump control, the heater pump is programmed to continue running for an optimum period of time in order to absorb the residual heat from the combustion chamber and use it in the system. The pump then shuts off until the next call for heat is received from the tankstat. ELECTRONIC IGNITION The intermittent ignition device conserves energy by automatically extinguishing the pilot when desired temperature is reached. When additional heat is needed, the pilot re-ignites electrically, eliminating costs of maintaining a constant pilot. To assure safe operation, the gas valve cannot open until the pilot lights and is proven. Economaster Control Fig # 9331 Ignition Module Electronic Safety Fig. # 8929.1 27
TANKSTAT TEMPERATURE CONTROL This is a bulb immersion type device that will regulate the water temperature in the storage tank. When the water temperature rises to the set point, the switch opens and shuts off the main burners. As the water cools down, the switch closes and turns on the main burners again to maintain the desired water temperature. FLOW SWITCH Dual purpose control shuts off heater in case of pump failure or low water flow condition. Factory mounted on all boilers except 136 and wired in series with main gas valve. NOTE: Flow switch will not operate if flow is less than 12 GPM. Fig. # 8643 Temperature Control Fig. #9317 HIGH LIMIT The high limit is also a bulb immersion type device that limits the water temperature in the heater outlet. It will shut off the main burners when the heater outlet water temperature exceeds the high limit setting, and cycles on again when the water temperature drops to the set point, less the differential. Models are equipped with manual reset high limit on all models except 136. Model 136 is equipped with an automatic reset high limit. Flow Switch HIGH LIMIT (Manual Reset) The manual reset high limit is similar to the automatic reset high limit, except the reset button on the front of the case must be pushed in to allow the main burners to operate again after a high limit shutdown. Models are equipped with manual reset high limit. The temperature setting is usually set 30 to 40 F above the operating temperature. Fig. # 9314 Manual Reset High Limit 28
100% PILOT SAFETY (IID Units) All heaters employ electronic devices, which close the main gas valve within 8/10 of a second whenever the pilot flame is interrupted. Pilot flame is automatically lit when the device is powered. Unit performs its own safety check and opens the main valve only after the pilot is proven to be lit. ELECTRICAL Heater electrical characteristics are Primary: 115 volt 60 Hz 1 phase. Secondary: Control Circuit: 24 volts. CAUTION: All wires prior to disconnection when servicing controls. Wiring errors can cause improper and dangerous operation. Verify proper operation after servicing. DANGER - SHOCK HAZARD make sure electrical power to the heater is disconnected to avoid potential serious injury or damage to components. The heater is normally wired for 120 Volts. The voltage is indicated on the tie-in leads. Consult the wiring diagram shipped with the boiler in the instruction packet. The "TH" leads are for the remote tank control connections 24 Volts are supplied to this connection through the heater transformer. DO NOT attach line voltage to the "TH" leads on sized 133-1826. Before starting heater check to insure proper voltage to boiler and pump. Single Stage Tankstat NOTES: 1. Field Installed ground to inside of junction box. 2. If any of the original wire as supplied with the heater must be replaced, it must be replaced with 105 C wire or its equivalent. WARNING: Before starting check to insure proper voltage is supplied to heater and pump. Heater must be electrically grounded in accordance with the National Electrical Code ANSI/NFPA No 70 latest edition. Use wiring diagram supplied with the heater. START-UP 1. Fill system with water, flush, to remove particles and other foreign objects that can cause pump damage. 2. Check electric supply characteristics a. Voltage to heater: 115 volts 60 Hz. 1 phase 15 amp circuit breaker. b. Voltage to pump: 3. Set operating and limit controls. ON-OFF OPERATION Set storage tank tankstat to desired temperature. This is the operating control. See Operation sequence, page 22. Single Stage Tankstat HEATER DPST TANKSTAT CONTROL WIRING Heater must be electrically grounded in accordance with National Electrical Code ANSI/NFPA No. 70. 29
To meet commercial water use needs, the thermostat on this water heater is adjustable up to 210 F. However, water temperatures over 125 F. can cause severe burns instantly or death from scalds. This is the preferred starting point for setting the control for supplying general purpose hot water. Safety and energy conservation are factors to be considered when setting the water temperature on the thermostat. The most energy efficient operation will result when the temperature setting is the lowest that satisfies the needs consistent with the application. General Safety Precautions The following chart details the relationship of water temperature and time with regard to scald injury and may be used as a guide in determining the safest water temperature for your applications. Temperature Time to Produce Serious Burn 120 F. More than 5 minutes 125 F. 1-1/2 to 2 minutes 130 F. About 30 seconds 135 F. About 10 Seconds 140 F. Less than 5 seconds 145 F. Less than 3 seconds 150 F. About 1-1/2 seconds 155 F. About 1 second Table courtesy of Shiners Burn Institute TIME/TEMPERATURE RELATIONSHIPS IN SCALDS The temperature of the water in the water heater can be regulated by setting the temperature dial on front of the thermostat. To comply with safety regulations the thermostat was set at its lowest setting before the water heater was shipped from the factory. The illustration below illustrates the thermostat and how to adjust the water temperature. Water temperature over 125 F can cause severe burns instantly or death from scalds. Children, disabled and elderly are at highest risk of being scalded. To adjust the water temperature, insert a small straight screwdriver into slotted screw in hole in front of thermostat and turn wheel to desired setting. Thermostat is adjustable up to 210 F. CAUTION!! - Hotter water increases the risk of SCALDING! See instruction manual before setting temperature at water heater. Feel water before bathing or showering. Temperature limiting valves are available, see manual. Maximum water temperatures occur just after burner has shut off. To find hot water temperature being delivered, turn on a hot water faucet and place a thermometer in the hot water stream and read the thermometer.! DANGER There is a Hot Water SCALD Potential if the thermostat is set too high. NOTE: When this water heater is supplying general purpose hot water requirements for use by individuals, a thermostatically controlled mixing valve for reducing point of use water temperature is recommended to reduce the risk of scald injury. Contact a licensed plumber or the local plumbing authority for further information. 30
LIGHTING INSTRUCTIONS FOR HEATERS WITH ELECTRONIC IGNITION (IID) For Models with Manual Gas Valves 512, 627, 726 FOR YOUR SAFETY READ BEFORE OPERATING WARNING:If you do not follow these instructions exactly, a fire or explosion may result causing property damage, personal injury or loss of life. A. This appliance is equipped with an ignition device which automatically lights the pilot. Do not try to light the pilot by hand. B. BEFORE OPERATING Smell all around the appliance area for gas. Be sure to smell next to the floor because some gas is heavier than air and will settle on the floor. WHAT TO DO IF YOU SMELL GAS * Do not try to light any appliance. * Do not touch any electric switch: do not use any phone in your building. * Immediately call your gas supplier from your neighbor s phone. Follow the gas supplier s instructions. * If you cannot reach your gas supplier, call the fire department. C. Use only your hand to push in or turn the gas control knob. Never use tools. If the knob will not push in or turn by hand, do not try to repair it, call a qualified service technician. Force or attempted repair may result in a fire or explosion. D. Do not use this appliance if any part has been under water. Immediately call a qualified service technician to inspect the appliance and to replace any part of the control system and any gas control which has been under water. OPERATING INSTRUCTIONS 1. STOP! Read the safety information above on this label. 2. Set the thermostat on the lowest setting. 3. Turn off all electric power to the appliance. 4. This appliance is equipped with an ignition device which automatically lights the pilot. Do not try to light the pilot by hand. 5. Remove boiler door panel. 6. For Robertshaw gas valve: Turn gas control knob clockwise to OFF. For Honeywell Gas Valve: Turn gas control knob clockwise to OFF". Make sure knob rest against stop. For Honeywell Gas Valve: Push in gas control knob slightly and turn clockwise to OFF. Knob cannot be turned to OFF unless knob is pushed in slightly. Do not force. 7. Wait five (5) minutes to clear out any gas. Then smell for gas, including near the floor. If you smell gas, STOP! Follow B in the safety information previously stated. If you do not smell gas, go to the next step. 8. For Robertshaw Gas Valve: Turn gas control knob counter clockwise to ON. For Honeywell Gas Valve: Turn gas control knob counter clockwise from OFF until it stops. Push in gas control knob and continue rotating counter clockwise to ON position. Make sure knob rest against stop. GAS CONTROL KNOB SHOWN IN "ON" POSITION GAS INLET Fig. # 8082 9. Replace boiler door panel. 10. Turn on all electric power to the appliance. 11. Set thermostat to desired setting. 12. If the appliance will not operate, follow the instructions To Turn Off Gas To Appliance and call your service technician or gas supplier. GAS CONTROL KNOB SHOWN IN "ON" POSITION GAS INLET Fig. # 8080 1. Set the thermostat to the lowest setting. 2. Turn off all the electric power to the appliance if service is to be performed. 3. Remove door panel. 4. For Robertshaw Gas Valve: Turn gas control knob clockwise to OFF. TO TURN OFF GAS TO APPLIANCE For Honeywell Gas Valve: Turn gas control knob clockwise to OFF. Make sure knob rest against stop. For Honeywell Gas Valve: Push in gas control knob slightly and turn clockwise to OFF. 5. Replace heater door panel. 31
LIGHTING INSTRUCTIONS FOR HEATERS WITH ELECTRONIC IGNITION (IID) FOR MODELS WITH AUTOMATIC GAS VALVES 726-1826 1. Close all gas valves. Turn off electric power supply. Wait five (5) minutes. 2. Open manual pilot valve. Turn on electric power. Pilot is automatically lighted. 3. Open main gas valve. 4. Set temperature controls to desired temperature. TO SHUT DOWN Close all manual gas valves. Turn off electric power. PILOT SHUT-OFF VALVE CONTROL SHOWN IN THE "ON" POSITION TO PILOT(S) MAIN GAS SHUT-OFF VALVE SHOWN IN THE "ON" POSITION 32
INSPECTION AND MAINTENANCE PROCEDURES It is a good practice to make a periodic inspection of the heater. It is recommended that the home owner or user checks the heater after the first and third month of operation, and then on an annual basis, or more often if desired. It is also recommended to have a qualified service agency check the heater before each heating season, or at anytime there may be an indication of a problem. 1. Keep heater area free from combustibles and flammable liquids. 2. Be certain that All combustion and ventilation air openings are free and clear of all obstructions. Screens, covering same, must be clean. Monthly: 1. Make visual inspection of burner flames. Fig. #8144 a. Flame should be blue with light yellow tips. b. Yellow flame indicates clogged air openings. c. Lifting of flame indicated high gas pressure. Check using manometer at 1/8 in. NPT tapping located between the gas valve and the burners. Pressure should be 3.7 in. W.C. 2. Inspect and operate all controls and gas valves. 3. Visually inspect system for water leaks Six Months: 1. Heat Exchanger Surfaces. a. Shut off electric and gas supply to heater. b. Examine external surfaces 2. Preliminary examination maybe done by using a mirror and a light in the burner area. 3. Remove venting, heater jacket top, flue collector and heat exchanger baffles. Remove inspection baffles. c. If surfaces are sooted or foreign material is lodged in fins, cleaning is required. To clean: A. Remove burner tray. - Disconnect gas control valves and pilot valves by breaking at unions. - Disconnect wiring from gas valves. - Remove burner tray retention screws. - Slide tray from heater carefully to avoid disturbing or damaging IID. B. Remove tube bundle. - Disconnect inlet-outlet header by removing flange nuts and retaining bolts. - Slide tube bundle away from inlet-outlet header, taking care to avoid damage to refractory and sheetmetal. - Washdown external surfaces of tube bundle. - Inspect interior surfaces of tubes. Clean deposits over 1/16" thickness. - Clean tubes using tube cleaning kit. C. Ream tubes by using auger bit. D. Complete cleaning by wire brushing to remove all debris. E. Immerse tube bundle in non-inhibited descale solvent. NOTE: DO NOT wire brush external surfaces. Steam cleaning is a recommended procedure. F. Replace tube bundle using the reverse of the above procedures. G. Before replacing burner tray clean burners. 4. Flow switch should be removed and checked. 5. Low water cutout, if provided, should be removed and checked. 33
DANGER: Keep heater area clear and free from combustibles and flammable materials. Do not obstruct the flow of combustion and ventilating air into the heater enclosure. Failure to observe these safety precautions can cause fire, explosion, or asphyxiation. 1. Burner Inspection Clean the main burners and air louvers of dust, lint and debris. With burner in operation, make a visual check of the burner flame and the pilot flame (when equipped). Yellow flames indicate some restriction of combustion air openings. A bright orange, luminous flame is not normal and can cause sooting under prolonged operation. Should this condition be observed, contact immediately a qualified service agency to correct the problem. 2. Venting System Inspection Visually inspect the venting system. Make sure the vent connections are secure and have not become disengaged. Look for any indication of corrosion, or carbon (soot) streaks which could cause leakage of products of combustion into the living space. Inspect the vent terminal outside the building. Make sure it is not damaged to cause blockage or restriction of the flue gas. Observe for any indication of soot. The presence of soot accummulation in the vent terminal would indicate an abnormal operating condition. This should be investigated and corrected by a qualified service agency. 3. Circulator (Water Pump) Inspection The circulator is permanently lubricated and thus, will not require any lubrication. Inspect for evidence of water leakage. This should be corrected to prevent any possible damage to electrical components of the boiler. CAUTION: In case of a prolonged power failure during freezing weather conditions, heater and piping system must be drained completely to avoid possible damage to the system. To prevent the potential freezing damage to the system, it is recommended that the following system shut down procedure be performed. SYSTEM SHUT DOWN PROCEDURE 1. Set the thermostat to "OFF" or the lowest setting. 2. Turn off all electric switches to the heater. 3. Turn off all gas valves supplying gas to the heater. Refer to operating instruction label on the heater. 4. Shut off the water supply to the heater piping system loop. 5. Open drain valve on the heater to remove water from the heater and the piping circuits. NOTE: It may be necessary to open the purge valves and/or manual air vents to facilitate complete drainage of water from the heating system. 4. Service Assistance If service is required on the heater, contact your local service agency. It is important and very often will save time if you state the model number, serial number and type of gas used. This information will be found on the nameplate of the heater. Fig. #8204.1 34
PROBLEM When thermostat is turned on nothing happens. Thermostat in on position causes relay and pump to operate, but heater does not fire. Continuous shut down of low water cut off. TROUBLE SHOOTING CAUSE IID Pilot is not lit.. No power to the heater. Trans- Bad former Inoperative thermostat Inoperative toggle switch Inoperative relay "A" valve closed Plugged bleed line Flow switch open. Broken pump coupler Shut down on low water cutoff, caused by air Gas valve defective. Low water due to leaking Air in system. SOLUTION Check pilot gas line. Check the circuit breaker, outdoor controller, etc., upstream of heater. If power to Leads L1 and L2 of transformer, but no power on 24V side, replace. Jumper thermostat, replace with new if heater fires. If power to toggle switch, but not through switch, replace. If power to relay, but not operating, replace. Open "A" valve. Loosen bleed line and clean. Low flow. Bleed air from the system. Adjust bypass valve to allow proper flow to activate the flow switch. If flow problem persists due to system design, primary-secondary pumping should be considered. Replace coupler. Inspect bearing assembly, and if frozen lubricate or replace. Bleed air reset button. Check for power to gas valve. If valve has power but will not open, replace the valve. Inspect for leakage and repair. Inspect for leakage and repair. Install an automatic air vent in top of low water cutoff. 35
Problem 1. Heater will not operate: TROUBLE SHOOTING Possible Cause Electrical: Main power Manual reset switch. Operating controller. Controller in-operative. Flow Switch Mechanical: Gas Line Plugged bleedline on pressure regulator, gas valves, etc. Broken pump coupler. Gas valve will not open: 1. Diaphram type. Action Check circuit breaker, fuses, etc. Power at boiler control switch should be 115 volts. Check all controls. If reset is tripped determine reason and correct. Check power to all controls with voltmeter. Adjust to desired operating temperatures. Remove sensor. Check for immersion or sensing. Replace if faulty. Check pump for operation. Open shutoff cock(s) Loosen bleed line and clean. Check reason for failure. Inspect bearing assembly, shaft and impeller. Replace coupling. Check bleed line. Clean. Check solenoid. Replace if defective. 2. Pilot burner will not light 2. Motorized type Check auxiliary switches. a. Auxiliary switch; b. Valve closed switch. Power should be 115 volts. Note: Actuator is not field repairable. If problem is other than switch(es) replace. 3. Combination type Check controller. Intermittent Ignition Module (IID) Check power to 25 VAC input terminal 1. If 25 VAC: - Check for 1/8" spark @ pilot. a. Spark ok: Check gas supply. Burner orifice. Dampness @ electrode or high tension wire. Check for 25 VAC @ PV; MV/PV terminals. 1. Voltage @ 25 VAC - Replace pilot valve. 2. Voltage not @ 25 VAC - Replace module. 2. No 25 VAC @ input terminal. - Check transformer output. a. 25 VAC Check limit circuit. b. No 25 VAC Replace transformer. 36
Electrical continued 3. Pilot lights - 4. Pilot lights - Main burner cyles. Intermittent Ignition Module Poor ground connection Main burners do not light. 3. Mechanical Modulating Valve. 4. Failure to pump. 5. Pump capacity insufficient. 6. Rapid coupling wear. 7. Pump loses prime. 8. Overload. 9. Mechanical noise. Check ground connection. Install or replace. Check for spark 1. Spark stays on while pilot is on. Check for loose ignition wire. Check for poor ground. Check flame coverage of both spark and grounded electrodes. If okay replace ignition module 2. Spark goes out and pilot stays on: Check voltage at MV; MV/PV terminals. - Voltage @ 24 VAC - replace main gas valve. - Voltage not at 24 VAC - replace module. Voltage should read 24 VAC. If valve does not open: 1st operator - replace valve 2nd operator- replace operator assembly. Check dial setting on valve and set to meet requirements. Unit keeps cycling on electrical limits - adjust temperature setting on valve. Pump not primed. Pump rotation wrong direction. Check motor leads- reverse to obtain proper rotation. Speed too low- Check for proper voltage at motor. Total head too high. Check for Air leaks in suction line. Clogged impeller. Strainer clogged. Excessive suction lift. Insufficient positive suction head. Total head greater than design. Worn impeller. Misaligned or bent shaft, Sagging motor mounts. Check for air leaks. Check water seal in stuffing box. Check suction lift and pump design curves. Check head on pump if too low throttle discharge. Check alignment. Correct if found. Check for vapor binding and reduce temperature to meet design. Check shaft and bearings. Check piping for correct alignment and support. 37
ELECTRICAL (ELECTRONIC IGNITION IID) MODELS 512-1826 C. Trouble shooting for S8600 control. Refer to the following chart for future servicing or the ignition control. WARNING HIGH VOLTAGE For qualified Technicians ONLY NOTE: Some heaters may be equipped with an ignition module that shuts off pilot gas if pilot fails to light. To reset, interrupt power to heater. Intermittent Pilot System TROUBLESHOOTING HONEYWELL S8600 START TURN GAS SUPPLY OFF. TURN THERMOSTAT (CONTROLLER) TO CALL FOR HEAT POWER TO MODULE (24 V NOMINAL) YES SPARK ACROSS IGNITER/SENSOR GAP YES NO NO NOTE: Before troubleshooting, familiarize yourself with the start-up and checkout procedure. Check line voltage power, low voltage transformer, limit controller, thermostat (controller) and wiring. Pull ignition lead and check spark at module. Spark Okay? YES Check ignition cable, ground wiring, ceramic insulator and gap, and correct. Check boot of the ignition cable for signs of melting or buckling. Take protective action to shield cable and boot from excessive temperatures. TURN GAS SUPPLY ON PILOT BURNER LIGHTS? YES SPARK STOPS WHEN PILOT IS LIT? YES MAIN BURNER LIGHTS? YES NO NO NO Check that all manual gas valves are open, supply tubing and pressures are good, and pilot burner orifice is not blocked. Check electrical connections between module and pilot operator on gas control. Check for 24 Vac across PV-MV/PV terminals on module. If voltage is okay, replace gas control; if not, replace module. NOTE: If S8600H goes into lockout, reset system. Lockout is used on L.P.G. models. Check continuity of ignition cable and ground wire. Clean flame rod. Check electrical connections between flame rod and module. Check for cracked ceramic flame rod insulator. Check that pilot flame covers flame rod and is steady and blue. Adjust pilot flame. If problem persists, replace module. Check for 24 Vac across MV-MV/PV terminals. If no voltage, replace module. Check electrical connections between module and gas control. If okay, replace gas valve or gas control operator, i.e. pilot gas valve, flow switch etc. SYSTEM RUNS UNTIL CALL FOR HEAT ENDS? YES NO NOTE: IF S8600H goes into lockout, reset system. Check continuity of ignition cable and ground wire. NOTE: If ground is poor or erratic, shutdowns may occur occasionally even though operation is normal at the time of checkout. Check that pilot flame covers flame rod and is steady and blue. If checks are okay, replace module. CALL FOR HEAT ENDS SYSTEM SHUTS OFF? YES NO Check for proper thermostat (controller) operation. Remove MV lead at module; if valve closes, recheck temperature controller and wiring; if not, replace gas valve. TROUBLESHOOTING ENDS Repeat procedure until troublefree operation is obtained. 38
WIRING DIAGRAM KEY 39
WIRING DIAGRAMS WIRING DIAGRAM - MODELS 136-264 WITH ENERGY PUMP SAVING CONTROL Fig. # 2288e 40
WIRING DIAGRAM - MODELS 331-399 Fig. # 1930e WIRING DIAGRAM MODELS 512-627 Fig. # 1924e 41
WIRING DIAGRAM MODELS 512-726 Fig. # 2194e WIRING DIAGRAM MODELS 726-825 Fig. #2297e 42
WIRING DIAGRAM MODEL 825-1826 WIRING DIAGRAM MODELS 962-1826 Fig. # 1967e 43
REPLACEMENT PARTS LISTS MODEL 136 GB ONLY 44
MODEL 136 GB ONLY 45
MODELS 181, 264, 331, 399 GB 46
47
MODELS 181, 264, 331, 399 GB 48
MODELS 181, 264, 331,339 GB 49
MODELS 512, 627, 726, 825 GB 50
MODELS 512, 627, 726, 825 GB 51
MODELS 512, 627, 726, 825 GB 52
MODELS 926-1826 GB 53
MODELS 926-1826 GB 54
MODELS 926-1826 GB NOTE: To supply the correct part it is important that you state the model number, serial number and type of gas. Any part returned for replacement under standard company warranties must be properly tagged with the return parts tag, completely filled in with the heater serial number, model number etc., and shipped to the Company freight prepaid. If determined defective by the Company and within warranty, the part will be returned in kind or equal substitution, freight collect. Credit will not be issued. 55